Polysilicon removal in word line contact region of memory devices

ABSTRACT

The present disclosure describes a patterning process for a strap region in a memory cell for the removal of material between polysilicon lines. The patterning process includes depositing a first hard mask layer in a divot formed on a top portion of a polysilicon layer interposed between a first polysilicon gate structure and a second polysilicon gate; depositing a second hard mask layer on the first hard mask layer. The patterning process also includes performing a first etch to remove the second hard mask layer and a portion of the second hard mask layer from the divot, performing a second etch to remove the second hard mask layer from the divot; and performing a third etch to remove the polysilicon layer not covered by the first and second hard mask layers to form a separation between the first polysilicon gate structure and the second polysilicon structure.

BACKGROUND

Non-volatile memory devices, such as flash memory, are used in a wide range of electronic devices or instruments (e.g., computers, cell phones, tablets, digital cameras, scientific instruments, etc.) to store data and/or programming instructions that can be subsequently read, erased, programmed, and saved when power is removed. Non-volatile memory (NVM) cells are thus an important component of modern chips.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the following detailed description when read with the accompanying figures.

FIGS. 1A and 1B are top views of polysilicon lines in a strap region of a memory cell, according to some embodiments.

FIG. 2A is a cross-sectional view of polysilicon lines in a strap region of a memory cell, in accordance with some embodiments.

FIG. 2B is a cross-sectional view of polysilicon lines in an area of a memory cell outside a strap region, in accordance with some embodiments.

FIG. 2C is a cross-sectional view of polysilicon lines in a strap region of a memory cell, in accordance with some embodiments.

FIG. 3 is a flow-chart of a patterning method for the removal of polysilicon material in a strap region of a memory cell, in accordance with some embodiments

FIG. 4 a cross-sectional view of an intermediate structure during a patterning method for the removal of polysilicon material in a strap region of a memory cell, in accordance with some embodiments.

FIGS. 5A, 5B, and 5C are cross-sectional views of intermediate structures during a patterning method for the removal of polysilicon material respectively in a strap area of a memory cell, in an area of the memory cell outside the strap region, and in an area outside the memory cell, in accordance with some embodiments.

FIGS. 6A and 6B are cross-sectional views of intermediate structures during a patterning method for the removal of polysilicon material respectively in a strap area of a memory cell and in an area of the memory cell outside the strap region.

FIGS. 7A and 7B are cross-sectional views of intermediate structures during a patterning method for the removal of polysilicon material respectively in a strap area of a memory cell and in an area of the memory cell outside the strap region.

FIGS. 8A, 8B, and 8C are cross-sectional views of intermediate structures during a patterning method for the removal of polysilicon material respectively in a strap area of a memory cell, in an area of the memory cell outside the strap region, and in an area outside the memory cell, in accordance with some embodiments.

FIGS. 9A, 9B, and 9C are cross-sectional views of intermediate structures during a patterning method for the removal of polysilicon material respectively in a strap area of a memory cell, in an area of the memory cell outside the strap region, and in an area outside the memory cell, in accordance with some embodiments.

FIG. 10A is a cross-sectional view of a contact formed on a strap region of a memory cell, in accordance with some embodiments.

FIG. 10B is a cross-sectional view of a contact formed in an area of a memory cell outside a strap region, in accordance with some embodiments.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, the formation of a first feature on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features are disposed between the first and second features, such that the first and second features are not in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.

The term “nominal” as used herein refers to a desired, or target, value of a characteristic or parameter for a component or a process operation, set during the design phase of a product or a process, together with a range of values above and/or below the desired value. The range of values can be due to slight variations in manufacturing processes and/or tolerances.

In some embodiments, the terms “about” and “substantially” can indicate a value of a given quantity that varies within 5% of the value (e.g., ±1%, ±2%, ±3%, ±4%, ±5% of the value). These values are merely examples and are not intended to be limiting. The terms “about” and “substantially” can refer to a percentage of the values as interpreted by those skilled in relevant art(s) in light of the teachings herein.

Flash memory is a type of non-volatile memory that stores information in an array of memory cells made from floating-gate transistors. Each memory cell resembles a metal-oxide-semiconductor field-effect transistor (MOSFET) except that the transistor has two gates instead of one. The memory cells operate as an electrical switch in which current flows between two terminals (e.g., a source and a drain) and is controlled by a floating gate (FG) and a control gate (CG) made of polysilicon. The CG is similar to the gate in other MOS transistors, but below it, there is the FG insulated all around by an oxide layer. The FG is interposed between the CG and the MOSFET channel. Because the FG is electrically isolated by its insulating layer, electrons placed on it are trapped. When the FG is charged with electrons, this charge screens the electric field from the CG, thus increasing the threshold voltage (VT1) of the memory cell. If there is charge present in the FG, a higher voltage (VT2) must be applied to the CG to make the channel conductive. In order to read a value from the transistor, an intermediate voltage between the threshold voltages (VT1 & VT2) is applied to the CG. If the channel conducts at this intermediate voltage, the FG is considered uncharged because if it was charged, there would be no current flow in the channel between the source and the drain terminals. In this situation, a logical “1” can be interpreted from this condition of the FG. If the channel does not conduct at the intermediate voltage, this situation indicates that the FG is charged; here, a logical “0” can be interpreted from this condition of the FG. The presence of charge on the FG is “sensed” by determining whether there is current flowing through the transistor when the intermediate voltage is applied on the CG. In a multi-level cell device, which stores more than one bit per cell, the amount of current flow can be sensed (versus simply determining whether the presence or absence of current flow), in order to determine more precisely the level of charge on the FG.

Within the flash memory cell area, the transistor gates are formed as densely packed lines referred to as polysilicon lines. The polysilicon lines are parallel to one another and are separated by a spacing. Voltage application to the CG portion of the polysilicon lines is achieved via contacts formed on areas of the CG polysilicon lines that act as contact landing pads. These contact landing pads are wider than the rest of the polysilicon line to facilitate the formation of the contact and are referred to as “contact regions” or “strap regions.” It is at the strap locations where the spacing is the narrowest between two neighboring polysilicon lines, according to some embodiments.

With each technology generation (node), the spacing between adjacent polysilicon lines decreases to increase the density of the memory cell and to improve the memory device's storage capacity. As a result, the area between neighboring polysilicon lines becomes increasingly challenging to pattern—e.g., selectively remove any deposited material (e.g., polysilicon). This is critical for the strap regions where the polysilicon line spacing between neighboring lines is the narrowest. Residue left behind between the tightly packed polysilicon lines can cause “bridging,” which can result in electrical shorts.

To address the aforementioned shortcomings, this disclosure is directed to a patterning process that removes excess material between polysilicon lines in the vicinity of the strap regions of memory cells and reduces (or eliminates) residue left behind by the removal process. In some embodiments, the residue reduction (or elimination) is accomplished by photolithography and etching operations that facilitate the removal process of excess material between tightly spaced adjacent polysilicon lines.

FIG. 1A is a partial top view of a memory cell (e.g., a flash memory cell) 100A where polysilicon lines 110 are formed parallel to each other at a nominal spacing d. Polysilicon lines 110 feature wider portions (e.g., strap regions or contact regions 120) to facilitate the formation of contacts not shown in FIG. 1A. In some embodiments, the spacing between adjacent polysilicon lines in the vicinity of contact regions 120 is reduced from d to d′. In some embodiments, d′ is the minimum spacing between two neighboring polysilicon lines 110. In some embodiments, contact regions 120 are intentionally offset in the y-direction to allow tighter spacing d between adjacent polysilicon lines 110 as shown in FIG. 1. Further, this design allows the formed contacts to be adequately separated to avoid bridging between the contacts. The layout of memory cell 100 is not limited to the depiction of FIG. 1, and alternative layouts are possible. For example, contact regions 120 from adjacent polysilicon lines 110 can be formed with no y-direction offset as shown in FIG. 1B for memory cells 100B and 100C. The layouts shown in FIG. 1B are within the spirit and the scope of this disclosure and the embodiments described herein are equally applicable to layouts 100A, 100B, and 100C, or variations thereof.

Each polysilicon line 110 represents a gate stack structure that is shared among several transistors formed within a flash cell. Further, each polysilicon line 110 includes a CG and a FG structure not shown in FIGS. 1A and 1B. Both the CG and FG structures are made of polysilicon and are positioned parallel to each other. As shown in FIGS. 1A and 1B, polysilicon lines extend lengthwise along the y-direction. Only selective components of memory cells 100A-C are shown in FIGS. 1A and 1B and other components, features, or layers are not shown for simplicity. These other layers include, but are not limited, to isolation regions, capping layers, spacers, additional polysilicon features (e.g., erase gates), doped regions, dielectric layers, contacts, etc. These other components, features, or layers are within the spirit and the scope of this disclosure.

In some embodiments, spacing d ranges between about 400 nm and 500 nm while spacing d′ ranges between about 200 nm and about 300 nm depending on the cell layout. The aforementioned ranges are not limiting and other values or ranges for spacing d and d′ are possible. These other values or ranges are within the spirit and the scope of this disclosure. In some embodiments, spacing d and d′ are governed by design rules set by a particular technology node. In referring to FIG. 1A, contact regions 120 of polysilicon lines 110 are offset in the y-direction by distance L, which is larger than spacing d′. By way of example and not limitation, distance L can be about 600 nm. Gate contacts are formed on polysilicon lines 110 within the designated contact regions 120. Each gate contact allows simultaneous control of multiple transistor gates. In other words, several gate structures can be “strapped” together and controlled with the same signal. Contact regions 120 may also be referred to as “strap” or “strap location.” In some embodiments, the contacts formed in contact regions 120 provide, for example, a word line electrical signal to the CG of the transistor.

By way of example and not limitation, FIG. 2A is a cross-sectional view of two neighboring polysilicon lines/gate structures 110A and 110B. In some embodiments, FIG. 2A is a cross-sectional view of FIG. 1A along cut line A-B prior to the formation of a CG contact on gate structure 110B. As discussed above with respect to FIG. 1, in the vicinity of contact region 120, one of the polysilicon lines/gate structures is wider than the other. In the example of FIG. 2A, gate structure 110B is wider than gate structure 110A because FIG. 2A is a cross-sectional view along contact region 120 of gate structure 1101B. Each gate structure includes a CG and one or more FGs isolated via a dielectric layer 210. Further, each CG in gate structures 110A and 110B is isolated via nitride layers 220. By way of example and not limitation, nitride layers 220 can include silicon nitride, and dielectric layer 210 can include silicon oxide. In some embodiments, gate structures 110A and 110B are formed on semiconductor substrate 230 as shown in FIG. 2A. In other embodiments, gate structures 110A and 110B are formed on isolation regions, such as shallow trench isolation regions. In some embodiments, gate structures formed in areas outside contact region 120 (e.g., outside the strap region and within the memory cell) can look different than gate structure 110A or 110B. For example, such gate structures may feature a single FG that extends along the entire width of the CG in the x-direction as shown in FIG. 2B for gate structures 110C and 110D.

In referring to FIG. 2A, gate structures 110A and 110B are separated by a polysilicon layer 200, which laterally fills the space between “internal” sidewall surfaces of gate structures 110A and 110B. Due to spacing d′ between gate structures 110A and 110B, polysilicon layer 200 features a divot 240 having a width w between about 30 nm and about 50 nm, and a height h between about 50 nm and about 70 nm. In some embodiments, the aspect ratio of divot 240 depends on spacing d′ between gate structures 110A and 110B. For example, as spacing d′ decreases (e.g., d′≈d), the aspect ratio of divot 240 increases. Conversely, as spacing d′ increases (e.g., d′≈d), the aspect ratio of the divot decreases (e.g., the aspect ratio can be less than about 1) as shown for divot 240′ in FIG. 2B where the spacing between adjacent gate structures 110C and 110D is equal to d. In some embodiments, the aspect ratio (h/w) of divot 240 shown in FIG. 2A (e.g., in the vicinity of contact region 120), ranges between about 2.3 and about 1. In some embodiments, divot 240′ shown in FIG. 2B (e.g., outside contact region 120) is wider (e.g., wider than about 50 nm) with a less aggressive aspect ratio than divot 240 (e.g., with an aspect ratio less than about 1).

In addition, erase gates (EG) structures are formed on “outside” sidewall surfaces of gate structures 110A and 110B. EG structures are formed from polysilicon, similar to the CG and FG as discussed above. In some embodiments, polysilicon layer 200 is subsequently etched to form a separation within spacing d′.

In some embodiments, FIG. 2C is a cross-sectional view of gate structures 110A′ and 110B′ of memory cell 100B shown in FIG. 1B along cut line C-D. Due to the layout differences between memory cells 100B and 100A, the cross-sectional view of FIG. 2C looks different from that of FIG. 2A with respect to gate structures 110A′ and 100B′. For example, cut line C-D traverses through contact region 120 of both gate structures 110A′ and 110B′; therefore, at the location of cut-line C-D gate structures 110A′ and 110B′ have substantially equal widths along the x-direction. In FIG. 2C, similar to FIG. 2A, polysilicon layer 200 disposed between gate structures 110A′ and 110B′ features a divot 240 due to spacing d′ as discussed above.

In some embodiments, a cross sectional view for memory cell 100C along contact regions 120 of adjacent polysilicon lines 110 would look similar to FIG. 2C.

In some embodiments, FIG. 2A and FIG. 2C are precursor structures (e.g., starting structures) for the embodiments described herein, which can be equally applied to memory cell layouts 100A/B/C and their variants thereof. For simplicity and without departing from the spirit and the scope of the disclosure, the embodiments described herein will be described with respect to memory cell 100A.

FIG. 3 is a flow chart of a fabrication method 300 describing a patterning process in the vicinity of contact region 120 between gate structures 110A and 110B shown in FIG. 1A according to some embodiments. Other fabrication operations may be performed between the various operations of method 300 and may be omitted merely for clarity and ease of description. These various operations are within the spirit and the scope of this disclosure. Additionally, not all operations may be required to perform the disclosure provided herein. Some of the operations may be performed simultaneously, or in a different order than the ones shown in FIG. 3. In some embodiments, one or more other operations may be performed in addition to or in place of the presently described operations. Method 300 will be described in reference to FIGS. 4A through 9C.

In referring to FIG. 3, method 300 begins with operation 310 and the process of forming an oxide and a nitride layer on gate structures separated by a polysilicon layer, such as gate structures 110A and 110B separated by polysilicon layer 200 shown in FIG. 2A. In some embodiments, the oxide layer is formed followed by the nitride layer. The oxide and nitride layers collectively form a hard mask stack that facilitates the patterning process of polysilicon layer 200. By way of example and not limitation, oxide layer 400 can be silicon oxide (SiO₂) thermally grown at about 680° C. to a thickness between about 30 nm and about 40 nm. Nitride layer 410 can include silicon nitride (Si₃N₄), or silicon oxynitride (SiON) grown at about 400° C. and at a thickness between about 10 nm and 20 nm. In some embodiments, nitride layer 410 is deposited with a substantially conformal process, such as a chemical vapor deposition process (CVD). The aforementioned materials, thicknesses, and growth conditions are not limiting and other materials, thicknesses, and growth conditions are possible. These other materials, thicknesses, and growth conditions are within the spirit and the scope of this disclosure.

FIG. 4 shows gate structures 110A and 110B after the deposition of oxide layer 400 and nitride layer 410 according to operation 310, according to some embodiments. In some embodiments, oxide layer 400 and nitride layer 410 cover the sidewall and bottom surfaces of divot 240 but do not fill divot 240 as shown in FIG. 4.

In referring to FIG. 3, method 300 continues with operation 320 and the process of forming a patterned photoresist layer on nitride layer 410. In some embodiments, prior to the deposition of photoresist layer, a bottom antireflective coating (BARC) layer is interposed between the photoresist layer and nitride layer 410. BARC layer suppresses light reflections during the patterning process of the photoresist layer. Further, the BARC layer minimizes undesirable generation of standing waves during the photoresist patterning process. Standing waves can increase the edge and sidewall roughness of the resulting patterned photoresist structure. In addition, BARC layer forms a flat surface, on which the photoresist layer can be formed, by acting as a filler to fill small imperfections in the underlying layers, such as divot 240. By way of example and not limitation, the BARC layer can be an organic compound that includes carbon, hydrogen, and oxygen. In some embodiments, the BARC layer is spin-coated on gate structures 110A and 110B shown in FIG. 4 at a thickness of about 160 nm. FIG. 5A shows the resulting structure after the formation of BARC layer 500 and patterned photoresist layer 510 on nitride layer 410. In some embodiments, patterned photoresist layer 510 has a thickness of about 120 nm. The aforementioned thicknesses for BARC layer 500 and photoresist layer 510 are not limiting and other thicknesses are within the spirit and the scope of this disclosure.

In some embodiments, the formation of oxide layer 400 and nitride layer 410 (as described with respect to operation 310) and the formation of BARC layer 500 and patterned photoresist layer 510 (as described with respect to operation 320) are not exclusive to contact region 120. In other words, the aforementioned oxide, nitride, and photolithography layers (e.g., BARC layer 500 and patterned photoresist layer 510) can be concurrently formed over the entire chip area, including the entire area of the memory cell and the logic areas of the chip. For example, FIG. 5B shows the formation of oxide layer 400, nitride layer 410, BARC layer 500, and patterned photoresist layer 510 according to operations 310 and 320 on the structures shown in FIG. 2B (e.g., an area within the memory cell outside contact region 120). Accordingly, FIG. 5C shows oxide layer 400, nitride layer 410, BARC layer 500, and photoresist layer 510 deposited in a logic area of the chip outside the memory cell. As shown in FIG. 5C, and during operation 320, photoresist layer 510 on the logic area of the chip is not patterned according to some embodiments. This is intentional since no features are being formed in the logic area during the subsequent operations.

In referring to FIG. 3, method 300 continues with operation 330 and the process of etching the BARC layer to form opening 600 to expose a portion of nitride layer 220 over polysilicon layer 200 as shown in FIG. 6A. In some embodiments, additional openings (e.g., like opening 600) can concurrently be formed in other locations of the memory cell outside contact region 120—e.g., as shown, for example, in FIG. 6B where opening 600′ is formed between gate structures 110C and 110D. In some embodiments, opening 600, as compared to other openings formed outside contact region 120 (e.g., 600′), can have a shorter width 600 w along the x-direction due to the limited spacing d′ between gate structures 110A and 110B. For example, 600 w shown in FIG. 6A (e.g., within contact region 120) can be equal to or less than 600′w (of FIG. 6B) formed in a different area of the memory cell outside contact region 120. Further, opening 600 shown in FIG. 6A exposes a sidewall portion and a bottom surface portion of divot 240 which can be more challenging to etch in a subsequent operation. In contrast, opening 600′ in FIG. 6B exposes only a bottom surface portion of divot 240′, which can be less challenging to etch in a subsequent operation.

In some embodiments, during the formation of openings 600 and 600′ in the memory cell areas, the logic area of the chip remains masked by BARC layer 500 and photoresist layer 510 as shown in FIG. 5C. Consequently, no openings are formed in the logic area of the chip during operation 330 of method 300.

In referring to FIGS. 3 and 7A, method 300 continues with operation 340 and the process of removing, through opening 600, the exposed portion of nitride layer 410 and the underlying oxide layer 400 to expose the polysilicon layer 200 between gate structures 110A and 110B. In some embodiments, during operation 340, exposed portions of nitride layer 410 and oxide layer 400 are also removed in other locations of the memory cell where openings, such as opening 600′, have been formed—for example, as shown in FIG. 6B. Contrary to FIG. 6B where opening 600′ exposes a portion of a single horizontal surface in divot 240′, etching nitride layer 410 and oxide layer 400 near contact region 120 shown in FIG. 7A can be more challenging because opening 600 exposes a combination of vertical and horizontal surfaces in divot 240. In some embodiments, etching nitride layer 410 and the underlying oxide layer 400 through opening 600 results in un-etched portions of oxide layer 400 as shown in FIG. 7A. This is undesirable because the presence of residual oxide layer in divot 240 can be detrimental to the subsequent removal of polysilicon layer 200. For example, residual oxide layer in divot 240 can result in polysilicon residue (e.g., un-etched portions of polysilicon layer 200), bridging (e.g., electrical shorts), or combinations thereof. In some embodiments, operation 340 fully removes the exposed portions of nitride layer 410 and the underlying oxide layer 400 through opening 600′ in memory cell areas outside contact region 120 as shown in FIG. 7B.

In some embodiments, the etching process used in operation 340 includes a dry etching process optimized to sufficiently remove nitride layer 410 and oxide layer 400 from divot 240. In some embodiments, the etching process includes a mixture of difluoromethane (CH₂F₂), sulfur hexafluoride (SF₆), helium (He), nitrogen (N₂), or the like. In some embodiments, the addition of N₂ in the etching chemistry increases the silicon-to-nitride selectivity—for example, from about 1:1 to about 1:6. Consequently, nitride layer 410 is efficiently removed during the etching process and less polysilicon is etched when exposed to the etching chemistry. By way of example and not limitation, the oxide-to-nitride selectivity is about 1:2.

According to some embodiments, the CH₂F₂ flow is about 50 sccm, the SF₆ flow is about 20 sccm, the He flow is about 100 sccm, and the N₂ flow is between about 20 sccm and about 100 sccm. In some embodiments, the duration of the etching process is about 32 s and is based on the silicon-to-nitride and the oxide-to-nitride selectivity. In some embodiments, the duration of the etching process is adjusted so that 80% of exposed oxide layer 400 is removed. In some embodiments, a bias of about 80 Volts is applied to substrate 230 during the etching process. Further, the etching process can be performed at a temperature range between about 40° C. and about 60° C. The aforementioned etching conditions are not limiting and other etching conditions are possible. These other etching conditions are within the spirit and the scope of this disclosure.

According to some embodiments, for a N₂ flow below about 20 sccm, the silicon-to-nitride selectivity is poor and polysilicon would be etched along with the nitride. As a result, defects can be formed in polysilicon layer 200. On the other hand, for a N₂ flow above about 100 sccm, polymer produced during the etching process can prematurely cease the etching process and nitride is not adequately removed.

Subsequently, photoresist layer 510 and BARC layer 500 are removed with an “ashing” (e.g., a high temperature oxidation process) and gate structures 110A and 110B are subjected to a wet etching process with diluted hydrofluoric acid (DHF) for a duration of about 20 s to ensure that un-etched portions of oxide layer 400 within divot 240 are removed. In some embodiments, the water-to-HF ratio in the aforementioned DHF solution is about 100:1.

During the wet etching process, nitride layer 400 is not etched, and therefore oxide layer 400 “masked” (e.g., covered) by nitride layer 400 (e.g., on gate structures 110A/B and EG) is not removed as shown in FIG. 8A. In some embodiments, exposed edges 800 of oxide layer 400 are laterally recessed (e.g., form an “undercut”) due to the etching isotropy of the wet etching process. An undercut in oxide layer 400 can also occur in other locations of the memory cell where edges of oxide layer 400 are exposed below nitride layer 400. The amount of the undercut may be controlled via the dilution ratio of the DHF and the exposure time (e.g., duration) of the wet etching process. In some embodiments, a similar undercut can be formed in other memory cell areas outside contact region 120 where oxide layer 400 is exposed in the wet etching process as indicated by exposed edges 800′ of oxide layer 400 in FIG. 8B.

In some embodiments, after operation 340 of method 300 shown in FIG. 3, additional photolithography and etching operations are performed in other areas of the chip (e.g., in the logic area) to remove a portion of nitride layer 410 and oxide layer 400 as shown in FIG. 8C. During these photolithography and etching operations the entire memory cell area is covered by fresh BARC and photoresist layers not shown in FIGS. 8A and 8B. These BARC and photoresist layers are subsequently removed with an ashing process prior to operation 350 of method 300 shown in FIG. 3.

In referring to FIG. 3, method 300 continues with operation 350 and the process of etching the exposed polysilicon layer 200 to form a separation or spacing 900 between gate structures 110A and 110B as shown in FIG. 9A. Prior to the polysilicon etch, nitride layer 410 shown in FIGS. 8A and 8B is removed. Removal of nitride layer 410 is achieved, for example, with a dry etching process selective towards nitride layer 410. By way of example and not limitation, the dry etching process can include organofluorine chemistry, such as tetrafluoromethane (CF₄) with hydrogen or oxygen, fluoroform (CHF₃), 1,1-difluoroethane (CH₃CHF₂), or combinations thereof. Other chemistries can also be used and are within the spirit and the scope of this disclosure.

Once nitride layer 410 is removed as shown in FIGS. 9A and 9B, portions of polysilicon layer 200 not masked by oxide layer 400 are removed (e.g., etched) with a dry etching process. In some embodiments, the dry etching process is anisotropic so that lateral etching of polysilicon layer 200 (e.g., in the x-direction) can be controlled. Further, the dry etching process is selective towards polysilicon layer 200. By way of example and not limitation, the dry etching chemistry can have a selectivity between polysilicon layer 200 and oxide layer 400 higher than about 100:1. In some embodiments, the etching chemistry includes a mixture of CH₂F₂, SF₆, He, N₂, and the like. By way of example and not limitation, the CH₂F₂ flow can be about 60 sccm, the SF₆ flow can be about 45 sccm, the He flow can be about 150 sccm, and the N₂ flow can be about 68 sccm. However, the aforementioned conditions are not limiting and other conditions may be used. These other conditions are within the spirit and the scope of this disclosure. In some embodiments, the etching process is end-pointed when dielectric layer 210 below polysilicon layer 200 is exposed through separation or spacing 900.

In some embodiments, separations or spacings 900 and 900′ are respectively formed as shown in FIGS. 9A and 9B. By way of example and not limitation, separation or spacing 900 has a width W between about 50 nm and about 100 nm and a height H between about 100 nm and about 120 nm. As shown in FIG. 9A, spacing d′ between gate structures 110A and 110B is larger than width W of separation or spacing 900 (e.g., d′>W). Accordingly, spacing d between gate structures 110C and 110D is larger than width W′ of separation or spacing 900′ (e.g., d>W′) as shown in FIG. 9B. In some embodiments, separations or spacings 900 and 900′ are formed so that a portion of polysilicon layer 200 remains on the inner sidewalls of gate structure 110A as shown in FIG. 9A and inner sidewalls of gate structures 110C and 110D as shown in FIG. 9B. The aspect ratio of separation or spacing 900 can be, for example, between about 1 and about 2.4.

In some embodiments, the polysilicon etching process in operation 350 can form polysilicon openings, including contact openings or other separation openings, in areas of the chip outside the memory cell—e.g., in the logic area of the chip as shown in FIG. 9C.

In some embodiments, after operation 350, oxide layer 400 is removed—for example, with a wet etching process using DHF—and a contact can be formed on contact region 120 of gate structure 1101B. By way of example and not limitation, FIG. 10A shows the structure of FIG. 9A after the formation of a contact 1000 on the widest portion of 110B (e.g., on contact region 120). By way of example and not limitation, contact 1000 can be formed by first depositing a dielectric layer 1010 to surround gate structures 110A/110B and fill separation or spacing 900, followed by a pattering process that forms a contact opening in dielectric layer 1010 on contact region 120 of gate structure 110B. The contact opening can be subsequently filled with a conductive material, such as a metal (e.g., tungsten (W), cobalt (Co), and the like). In some embodiments, an etch stop layer, not shown in FIG. 10, can be deposited on gate structures 110A/110B and separation or spacing 900 prior to the formation of dielectric layer 1010 to facilitate the formation of the contact opening for contact 1000. Formation of additional contacts on other portions of the memory cell, or other regions of the chip, is possible during the formation of contact 1000. For example, a contact 1000′ can be formed between gate structures 110C and 110D shown in FIG. 10B. Subsequently, metallization or wiring layers can be formed over gate structures 110A, 110B, 110C, and 110D. These additional metallization or wiring layers, which are not shown in FIGS. 10A and 10B, can be electrically coupled through contacts 1000 and 1000′ to the CG of gate structure 110B and source drain regions of substrate 230.

Various embodiments in accordance with this disclosure describe a patterning process for the strap region of a memory cell that removes excess material between polysilicon lines and reduces (or eliminates) residue left behind by the removal process. In some embodiments, the residue removal (or elimination) is accomplished by introducing photolithography and etching operations that facilitate the removal process of excess material between tightly spaced polysilicon lines. In some embodiments, the patterning process includes a hard mask photolithography and hard mask etching processes that remove the hard mask layers from divots in a polysilicon layers between polysilicon lines. In some embodiments, the etching process includes a dry etching process that targets nitride and oxide layers of the hard mask followed by a wet etching process that targets oxide layer of the hard mask.

In some embodiments, a method includes forming, on a substrate, a first polysilicon line with a first width and a second polysilicon line with a second width, where the first and second polysilicon lines are spaced apart by a polysilicon layer and each of the first and second polysilicon lines includes a contact region wider than the first and second widths. The method further includes depositing a mask layer on the first polysilicon line, the contact region of the second polysilicon line, and the polysilicon layer; and etching, from the polysilicon layer, the mask layer with a dry etching process to remove a portion of the mask layer and to expose a first portion of the polysilicon layer. Further, etching, from the polysilicon layer, unremoved portions of the mask layer with a wet etching process to expose a second portion of the polysilicon layer that is larger than the first portion, where the second portion is narrower than the polysilicon layer which is interposed between the contact region of the second polysilicon line and the first polysilicon line. The method also includes removing the exposed second portion of the polysilicon layer to form a separation between the contact region of the second polysilicon line and the first polysilicon line.

In some embodiments, a method includes depositing a first hard mask layer in a divot formed on a top portion of a polysilicon layer which is interposed between a first polysilicon gate structure and a second polysilicon gate structure; and depositing a second hard mask layer on the first hard mask layer, where the first and second hard mask layers cover sidewall and bottom surfaces of the divot. The method also includes performing a first etch to remove the second hard mask layer and a portion of the first hard mask layer from a first sidewall of the divot; performing a second etch to remove the second hard mask layer from the first sidewall and from a bottom surface of the divot; and performing a third etch to remove the polysilicon layer not covered by the first and second hard mask layers to form a separation between the first polysilicon gate structure and the second polysilicon structure.

In some embodiments, a structure includes a first polysilicon line and a second polysilicon line parallel to each other disposed on a substrate. The first and second polysilicon lines include a contact region and a non-contact region, where each contact region is wider than each non-contact region and where the contact region of the first polysilicon line is offset with respect to the contact region of the second polysilicon line. The structure further includes a polysilicon layer that is disposed on a sidewall of a non-contact region of the first polysilicon line and is opposite to the contact region of the second polysilicon line, and a space between the polysilicon layer and the contact region of the second polysilicon line. The structure also includes a contact disposed on the contact region of the second polysilicon line.

It is to be appreciated that the Detailed Description section, and not the Abstract of the Disclosure, is intended to be used to interpret the claims. The Abstract of the Disclosure section may set forth one or more but not all exemplary embodiments contemplated and thus, are not intended to be limiting to the subjoined claims.

The foregoing disclosure outlines features of several embodiments so that those skilled in the art may better understand the aspects of the present disclosure. Those skilled in the art will appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art will also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the subjoined claims. 

What is claimed is:
 1. A method, comprising: forming, on a substrate, a first polysilicon line with a first width and a second polysilicon line with a second width, wherein the first and second polysilicon lines are spaced apart by a polysilicon layer and each of the first and second polysilicon lines comprises a contact region wider than the first and second widths; depositing a mask layer on the first polysilicon line, the contact region of the second polysilicon line, and the polysilicon layer; etching, from the polysilicon layer, the mask layer with a dry etching process to remove a portion of the mask layer and to expose a first portion of the polysilicon layer; etching, from the polysilicon layer, unremoved portions of the mask layer with a wet etching process to expose a second portion of the polysilicon layer larger than the first portion, wherein the second portion is narrower than the polysilicon layer interposed between the contact region of the second polysilicon line and the first polysilicon line; and removing the exposed second portion of the polysilicon layer to form a separation between the contact region of the second polysilicon line and the first polysilicon line.
 2. The method of claim 1, wherein etching the mask layer comprises: removing a nitride masking layer disposed on an oxide masking layer, wherein the oxide masking layer is disposed on the first polysilicon line; and removing a portion the oxide masking layer, the contact region of the second polysilicon line, and the polysilicon layer.
 3. The method of claim 1, wherein etching the unremoved portions of the mask layer comprises etching an oxide masking layer disposed on the first polysilicon line, the contact region of the second polysilicon line, and the polysilicon layer.
 4. The method of claim 1, wherein depositing the mask layer on the polysilicon layer comprises covering, with the mask layer, sidewall and bottom surfaces of a divot formed on a top surface of the polysilicon layer.
 5. The method of claim 1, wherein etching the mask layer with the dry etching process comprises patterning a photoresist layer on the mask layer to expose an area of the mask layer over the polysilicon layer, wherein the exposed area of the mask layer is narrower than the polysilicon layer.
 6. The method of claim 1, wherein etching the unremoved portions of the mask layer with the wet etching process comprises forming an undercut in un-etched portions of the mask layer.
 7. The method of claim 1, wherein depositing the mask layer comprises: depositing an oxide layer on the first polysilicon line, the contact region of the second polysilicon line, and the polysilicon layer; and depositing a nitride layer on the oxide layer.
 8. A method, comprising: depositing a first hard mask layer in a divot formed on a top portion of a polysilicon layer interposed between a first polysilicon gate structure and a second polysilicon gate structure; depositing a second hard mask layer on the first hard mask layer, wherein the first and second hard mask layers cover sidewall and bottom surfaces of the divot; performing a first etch to remove the second hard mask layer and a portion of the first hard mask layer from a first sidewall of the divot; performing a second etch to remove the second hard mask layer from the first sidewall and from a bottom surface of the divot; and performing a third etch to remove the polysilicon layer not covered by the first and second hard mask layers to form a separation between the first polysilicon gate structure and the second polysilicon structure.
 9. The method of claim 8, further comprising forming a contact on the second polysilicon structure.
 10. The method of claim 8, wherein depositing the first hard mask layer comprises depositing an oxide layer on the top portion of the polysilicon layer.
 11. The method of claim 8, wherein depositing the second hard mask layer comprises depositing a nitride layer on the first hard mask layer.
 12. The method of claim 8, wherein performing the first etch comprises performing an etch with difluoromethane (CH₂F₂), sulfur hexafluoride (SF₆), helium (He), and nitrogen (N₂).
 13. The method of claim 8, wherein performing the first etch comprises using an etching chemistry comprising a nitrogen flow between about 20 sccm and about 100 sccm for a silicon-to-nitrogen etching selectivity of about 1 to
 6. 14. The method of claim 8, wherein performing the second etch comprises performing a wet etching process with diluted hydrofluoric acid (HF) for about 20 seconds.
 15. The method of claim 8, wherein performing the third etch comprises performing a dry etching process selective to polysilicon.
 16. The method of claim 8, wherein performing the third etch comprises forming the separation narrower than a distance between first and the second polysilicon gate structures.
 17. A structure, comprising: a substrate; a first polysilicon line and a second polysilicon line parallel to each other disposed on the substrate with each of the first and second polysilicon lines comprising a contact region and a non-contact region, wherein each contact region is wider than each non-contact region and wherein the contact region of the first polysilicon line is offset with respect to the contact region of the second polysilicon line; a polysilicon layer disposed on a sidewall of a non-contact region of the first polysilicon line and opposite to the contact region of the second polysilicon line; a space between the polysilicon layer and the contact region of the second polysilicon line; and a contact disposed on the contact region of the second polysilicon line.
 18. The structure of claim 17, wherein the space has an aspect ratio between about 1 and about 2.4.
 19. The structure of claim 17, wherein a bottom surface of the space is polysilicon layer free.
 20. The structure of claim 17, wherein the second polysilicon line in the contact region comprises a contact gate and one or more floating gates. 